16
Hanson Building Products chimney solutions Uniclass L5211 CI/SfB Ng2 (47) August 2009 rediflow concrete gas flue system RED BANK ®
Hanson Building Products chimney solutionsUniclassL5211
CI/SfBNg2(47)August 2009
rediflow concrete gas flue systemRED BANK®
Rediflow Concrete Gas Flue System
2
Rediflow the complete gasflue block system
Hanson Red Bank’s range of
Rediflow pre-cast concrete gas
flue block system manufactured
to BS EN 1858 Chimney -
Components - Concrete flue blocks
(Type B flue blocks).
The innovative tongue and
groove design helps eliminate the
possibility of escaping flue
condensates and ensure the safe
discharge of the flue gases.
Energy Efficiency Rating
Current Potential
Very energy efficient – lower running costs
Not energy efficient – higher running costs
UK 2008 U
AB
CD
EF
G
(93-100)
(81-92)
(66-80)
(51-65)
(36-50)
(21-35)
(1-20)
EU Directive2002/91/EC
55
78
Energy Efficiency Requirements for New Dwellings
The latest 2006 revisions to Building Regulations ApprovedDocument L1A include strict rules on the calculation of carbonemissions from all new dwellings. Under current legislationthese are designed to ensure that carbon emissions arereduced by 20% compared to the 2002 Regulations.
As part of the Standard Assessment Procedures (SAP)secondary heating appliances have to be included in thecalculations. These extend an opportunity to specify highefficiency gas fired appliances that will help meet theGovernments target and gain carbon credits, whilst satisfyingpurchasers requirements for a ‘fireplace’ and focal point withassociated comfort and lifestyle benefits.
Contents
The complete product range 4-7
Detached property - typical flue system 8
Chimney construction & deep recess options 9
Semi-detached property - typical flue system 10
Timber framed property - typical flue system 11
Typical recess installations 12
Termination of flue systems 13
Installation, inspection & testing 14-15
Front and inside cover photo courtesy of:Paragon - Focus III HMVI Brass Antique Wellington Coals
3
The Benefits of Installing a Chimney
If secondary heating is not specified, the SAPcalculation used to determine carbon emissions‘defaults’ to electric as the secondary heating type.
Electricity is a carbon intensive energy source and by specifying a modern high efficiency gas firesubstantial carbon savings can be achieved. These carbon credits can then be used to offsetcosts of other aspects of the construction such as insulation and glazing.
Choosing the Secondary Heating Applianceat Planning Stage is Vital
To maximise the potential carbon savings andbenefits the correct flue size and secondaryheating appliance must be specified at the designstage. Although this decision has usually been leftuntil after completion of the building, it is essentialthat the most appropriate appliance is specified, if not the SAP calculation will default to carbonintensive electric heating or an inefficient open fire or appliance.
Appliance Choice and Application
Rediflow concrete gas flue blocks are suitable foruse with approved radiant and convector gas firesand appliances with flue outlets up to 125mm dia.These include many Inset Live Fuel Effect gas fireswith a rated imput of up to 7kW, dependent on theappliance manufacturers recommendations andapproval for use with pre-cast flue blocks. Gas FlueBlocks are not suitable for use with Decorative FuelEffect gas fires requiring a minimum 175mm int. da.flue. (see Hanson Red Bank’s range of Concreteand Clay Flue Liners for Multi-Fuel Applications).
RF1 ConcreteStarter Block
Rediflow Concrete Gas Flue System
The complete product range
142mm
115mm
405mm
325mm
222mm
RF1
400mm
270mm
222mm
490mm
200mm
415mm
142mm
222mm
490mm
115mm
RF2 ConcreteCover Block
RF21 Deep RecessConcrete Starter Block
RF22 Extra WideConcrete Cover Block
RF23 Extra WideConcrete Starter Block
RF24 Extra WideConcrete Cover Block
142mm385mm
222mm
270mm490mm
222mm
RF22
142mm490mm
222mm
RF24
RF2
RF3 222mm high coursing block with nib
142mm359mm
222mm
142mm359mm
147mm
142mm359mm
112mm
142mm359mm
72mm
RF3
RF4 high Plain Block without nib222mm high Coursing Block without Nib
142mm280mm
222mm
RF4
RF5 Concrete Side Offset Block120mm side offset
142mm400mm
222mm
120mm
side
offset
RF5
RF6 Concrete Rear Offset Block70mm rear offset
210mm280mm
222mm
70mmrearoffset
RF6
RF7 Vertical Exit BlockFor connection to twin wall metal flue pipe
181mm280mm
222mm
125mm int. diam.
161mm min. ext. diam.
RF7
210mm280mm
222mm
25mmrearoffset
RF12
RF21
RF23
Also available as a coursing block inthe following sizes:
72mm high Plain Coursing Block without nib112mm high Plain Coursing Block without nib147mm high Plain Coursing Block without nib
Also available: RF12 25mm Concrete Rear Offset BlockTo be used in conjunction with starterblocks in party wall situations
Also available as a coursing block inthe following sizes:
72mm high Coursing Block with Nib112mm high Coursing Block with Nib147mm high Coursing Block with Nib
142mm280mm
147mm
142mm280mm
112mm
142mm
72mm
280mm
4
5
RF8 Angled Exit BlockFor connection to twin wall metal flue pipe. May be used as angled entry block in conjunction with RF9
181mm280mm
230mm
111mm
125mm min. int. diam.
RF8
RF10 Concrete Corbel Block For extended corbel blocks see RF61, RF62 and RF63
RF11 Gas Lintel BlockMay be used to carry single skin of brickwork in front of flue
142mm280mm
222mm
76mm
100mm555mm
65mm
RF9 Reverse Rebate BlockTo be used in conjunction with inverted RF8
142mm280mm
222mm
RF9
RF11
RF10
RF61 Extended Corbel Block552mm wide Extended Corbel Block
Also available:
RF62 665mm wide ExtendedCorbel Block
RF63 778mm wide ExtendedCorbel Block
Also available:
RF66 625mm wide StainlessSteel Bed Reinforcement
RF67 737mm wide StainlessSteel Bed Reinforcement
RF64 Stainless Steel Strap UnitTo be used in conjunction with Extended Corbel Block andStainless Steel Bed Reinforcement
RF65 Stainless Steel Bed Reinforcement515mm wide Stainless Steel Bed Reinforcement
114 ContemporaryCanon Head ChimneyPot 300mm, 450mm and 600mm high
625 GC5 Insert Terminal125mm int. dia.
242mm552mm
140mm
242mm665mm
140mm
242mm778mm
140mm
RF29 High Density BlockTo be used in conjunction with starter blocks in party wall situations
100mm540mm
215mm
RF29
RF61
RF62 RF63
300mm515mm
60mm
300mm
625mm
60mm
m
300mm
737mm
60mm
1045mm
50mm
80mm
RF64
RF65
RF66 RF67
6
Rediflow Concrete Gas Flue System
RF34 Flue Block ConnectorTo be used in conjunction with RF7 and RF8
B = 125mm
113mm
B
RF35 - RF39 Twin Wall Pipe150mm to 1500mm
RF 35 1500mm length Twin Wall Flue PipeRF 36 900mm length Twin Wall Flue PipeRF 37 450mm length Twin Wall Flue PipeRF 38 300mm length Twin Wall Flue PipeRF 39 150mm length Twin Wall Flue Pipe
Int Ø 125mm
A
Int Ø
Timber frame products
FB1 150mm wide Flanking BlockTo be used in conjunction with RF1 Starter Blocks
FB1
FB2 163mm wide Flanking BlockTo be used in conjunction with RF2 Cover Blocks FB2
FB3 136mm wide Flanking BlockTo be used in conjunction with RF3 Bonded Blocks FB3
FB4 215mm wide Flanking BlockTo be used in conjunction with RF3 Bonded Blocks and RF8 Exit Block
FB4
FB6 Clay Flanking BlockTo be used in conjunction with RF21, RF22, RF23 and RF24 Deep Recess and Extra Wide Starter and Cover Blocks
FB6
FBL Top Lintel BlockFBL
FBZ Galvanised Steel ‘Z’ Section
FBZ
Add on range
RF28 RediflowFireproof Mortar580gm Tube Rediflow Fireproof Mortar
RF30 Rediflow Damp ProofInsulation Mat600mm (W) x 900mm (H) x 25mm (D)
To be inserted behind flue blocks inexternal wall situations
RF31 Rediflow Damp ProofInsulation Mat600mm (W) x 900mm (H) x 50mm (D)
To be inserted behind flue blocks inexternal wall situations
RF32 Rediflow Smoke Pellets6 13gm pellets per tube
NP1 Notice Plate andChecklist Pack
RF28
RF34
RF35
RF30
RF31
RF32
NP1
150mm
100mm
215mm
163mm
100mm
215mm
136mm
100mm
215mm
730mm
50mm
100mm
215mm
100mm
215mm
110mm
100mm
215mm
12
50
mm
125mm int. dia. Twin wall metal gas vent
7
125mm int. dia. Twin wall metal gas vent
RF40 450mm LengthAdjustable PipeC = 50 - 380mm
Dimension C is theamount another pipe canslide inside the adjuster
Low Resistance Ridge Tiles
450mm
C
Int Ø
RF70 300mm lengthadjustable pipeC = 50 - 230mmInt Ø 125mm
300mm
C
Int Ø
RF41 Adjustable Bend
0º
290mm
17
5m
m
165mm90º
RF48 Firestop Plate
460mm
RF44 Adjustable Wallband
RF47 Support Assembly
275mm
up to
RF45 Roof PlateTwo piece
460mm
191mm
50mm
460mm
RF46 Angled Flashing Kit 5° - 30°Complete with Storm Collar and Sealant
610mm
610mm
RF49 Angled Flashing Kit 5° - 45°Complete with Storm Collar and Sealant
RF53 Flat Roof Flashing KitComplete with Storm Collar and Sealant
610mm
150mm
610mm
460mm
250mm
460mm
RF50 GCI Terminal
RF42 Ridge Tile Adaptor
RF73 Ridge Tile AdaptorExtension BoxTo fit apex of steeply pitched roofs
640- 646 Clay Low ResistanceRidge TileAvailable in Half Round, Angle andPan Sections
Concrete Low ResistanceRidge TileAvailable in Half Round, Curved Angleand Segmental Sections
78mm
182mm
356mm
250mm
RF73
RF50
RF42
RF43
RF44
RF45
RF47
RF48
RF46
RF49
RF53
RF40
RF70
RF41
RF43 WallbandØ 125mm
Ø 125mm
Detached property – typical flue construction
Rediflow Concrete Gas Flue System
Damp ProofInsulation Mat
147mm high
RF3
641
RF2
RF44 Adjustable WallbandAlso available with 50mm extenson
RF41 Adjustable Bend0 - 90° Bend
RF30 Rediflow Damp Proof Insulation MatAlso available with 50mm deep insulation mat
RF8 Angled Exit Block
RF2 Cover BlockAlso available Deep Recess and Extra Wide cover blocks
RF1 Starter BlockIt is recommended that 3 starterblocks are used to form recess witha minimum 610mm high opening.
RF34 Flue Block Connector
RF5 Side Offset Block120mm side offset
641 Low Resistance TerminalAvailable in Half Round, Angle and Pan Sections
RF42 Ridge Tile Adaptor
RF3 147mm high BondedCoursing Block with nib Also available in 112 and 72mm high.
RF3 222mm high BondedBlock with nibMinimum of 2 straightblocks recommendedabove cover block beforeany offset blocks
8
RF35 1500mm length TwinAdjustable Flue PipeAlso available in 900, 450,300 and 150mm lengths
RF30
RF5
RF5
RF3
147mm highRF3
RF1
RF8
RF41
RF34
RF43
RF35
RF42
Detached property - masonry chimney termination
Damp ProofInsulation Mat
RF22 Deep Recess Cover BlockAlso available Standard and Extra Wide cover blocks
RF21 Deep Recess Starter BlockAlso available Standard andExtra Wide starter blocks
RF31 RediflowDamp Proof Insulation MatAlso available with 25mm thick insulation mat
RF21
RF61 552mm wide Extended Corbel BlockAlso available in 665 and 778mm wide
RF64 Stainless Steel Strap Unit
RF3 72mm high Coursing Block with nibAlso available in 147 and 112mm high
RF3 147mm high Bonded Coursing Block with nibAlso available in 112 and 72mm high
RF3 222mm high Bonded Block with nib
RF4 222mm high Plain Block without nibAlso available 147, 112 and 72mm highPlain Coursing Blocks without nib
RF7 Vertical Exit Block
RF65 515mm wide Stainless Steel Bed ReinforcementsAlso available in 625 and 725mm wide
RF22
RF3
RF3
RF30
RF64
RF61
RF4
RF65
RF4
RF7
114114 Contemporary Cannon Head Chimney Pot300mm, 450mm and 600mm high
625C GC5 Insert Terminal125mm int. dia.
9
147mm high
147mm high
222mm high
222mm high
Note: Brickwork used toshow the additional singleskin on face of flue blocks,but in practise this wouldalways be blockwork)
625C
Rediflow Concrete Gas Flue System
10
Semi-detached property – typical flue system
RF34 Flue Block Connector
RF3 147mm high Bonded Coursing Block with nibAlso available in 112 and 72mm high
RF3 222mm high Bonded Block with nib
RF2 Cover BlockAlso available Deep Recess and Extra Wide cover blocks
RF29 High Density Block
RF1 Starter BlockIt is recommended that 3 starter blocksare used to form recess with a minimum610mm high opening
RF8 Angled Exit Block
RF41 Adjustable Bend0º to 90º
RF44 Adjustable Wallband Also available with 50mm extension
RF36 900mm length Twin Wall Flue PipeAlso available in 1500mm, 450mm,300mm and 150mm lengths
RF 40 450mm length adjustable pipe
641 Low Resistance TerminalAvailable in Half Round,Angle and Pan Sections
RF42 Ridge Tile Adaptor
RF70 300mm length Adjustable PipeAlso available in 450mm length
147mm high
641
RF3
RF3
147mm highRF3
RF1
RF8
RF41
RF34
RF43
RF35
RF42
RF2
RF29
RF5RF3
RF3
RF40
RF29
11
Timber framed property - typical flue system
FBZ Galvanised Steel ‘Z’ Section
RF8 Angled Exit Block
RF2 Cover BlockAlso available Deep Recess and ExtraWide cover blocks used in conjunctionwith FB6 131mm wide flanking blocks
RF1 Starter BlockAlso available Deep Recess and ExtraWide starter blocks used in conjunctionwith FB6 131mm wide flanking blocks
RF3 222mm high Bonded Block with nib
FB3 136mm wide Flanking BlockFB1 150mm wide Flanking BlockFB2 163mm wide Flanking BlockFB4 215mm wide Flanking Block
RF43 Wallband Also available with 275mm extension
RF34 Flue Block Connector
FBL Top Lintel Block
RF41 Adjustable Bend0º to 90º
RF40 450mm length Adjustable PipeAlso available in 300mm length
RF35 1500mm length Twin Wall Flue PipeAlso available in 900mm, 450mm, 300mm and 150mm lengths
RF3
RF1
RF8
RF41
RF34
RF43
RF40
RF35
RF42
RF2
RF3
RF3
641
Rediflow Concrete Gas Flue System
Typical recess installations
RF1 Starter Blocks in external wall with 65mm cavityand 25mm thick damp proof insulation mat
RF1
RF30 DPM
275
Brickwork
12.5mmplasterboardon dabs
8mm renderscratch finish
RF21 Deep Recess Starter Blocks in external wall with100mm cavity and 50mm thick damp proof insulation mat
RF23 Extra Wide Starter Blocks on first floor ofexternal wall.
12.5mmplasterboardon dabs
8mm renderscratch finish
RF1 Starter Blocks in party wall situation with highdensity blocks, flues offset at 550mm centres
12.5mmplasterboardon dabs
8mm renderscratch finish
RF21
RF31 DPM
300
Brickwork
RF23
RF31 DPM
300
Brickwork
275mm min
12.5mm plasterboard(min 8kg/m2) on dabs
8mm render, scratch finish
Plaster fillet must be continuous around fire opening
RF29 High Density Block
RF1 Starter Block
12
Termination of flue systems
Metal Twin Wall Flue Pipe for Angled Exit Block
Low resistance ridge terminals offer a discrete exitpoint for the flue. Eliminating the need for achimney stack or external metal flue pipe.
Masonry Chimney
A traditional masonry chimney stack can beconstructed on top of a cavity wall using HansonRed Bank’s structural reinforcing kit. The Bedreinforcement and stainless steel straps securelyanchor the stack into the masonry below.
Metal Twin Wall Flue Pipe for Vertical Exit Block
If desired or where it is not possible for the flue toreach the ridge line, the twin wall metal flue pipe canpenetrate through the roof slope using an angledflashing kit and terminating at a GC1 terminal.
Prefabricated Chimney on ridge
A range of prefabricated chimney stacks with orwithout flue terminations are available. The stacksare available, finished with brick slips, preparedblock slips or prepared for render.
13
Rediflow Concrete Gas Flue System
Installation, inspection and testing
measurements for Tongue and Groove are in mm unless stated otherwise
612.5
8
R3
R3
12.5
R3
12
5
60o
60oFlue
3mm
8mm
3mm
Note:An 8mm bead offireproof mortar shouldbe laid into the rebate(see opposite).
• blocks to be laid rebate up with an 8mm fireproofmortar bead to be applied into the rebate (as shown).
• joints should be pointed and any surplus mortarremoved from the flueway during constructionleaving a smooth uniform surface.
• ensure joints are completely sealed with jointing compound.
• if the blocks and surrounding courses of masonryfail to meet exactly on no account attempt to cutthe blocks but trim the surrounding masonry to suit.
• a minimum air gap of 50mm must exist between theoutside of the flue and any combustible material.
• it is essential that during construction andappliance installation the commissioningrequirements laid down in BS 5440 : Part 1are strictly followed. This should include visualchecks, smoke and spillage checks.
• for further details refer to the “Installation,Inspection and Smoke Testing Procedures”included in the Checklist and NoticePlate Pack.
Approved Document ‘J’ (ADJ)2002 Edition of the Building Regulations 2000
A flue system correctly constructed and installed inaccordance with Building Regulations and ourrecommendations, using these components will meetall current statutory requirements. For each flue system it is a requirement that theinstaller completes a ‘Checklist’ and Notice Plate’
The Checklist should ensure that the construction ofthe flue has been completed in accordance withregulatory requirements and copies should beoffered to the Client, Building Control Body and/orMain Contractor.
The Notice Plate contains information essential tothe correct application and use of the flue andshould be robust, indelibly marked and securely fixedin a permanent position within the building.
A ‘Checklist and Notice Plate Pack’ List No. NP1 isavailable. This contains a checklist, notice plate andself-sealing laminate cover together with guidancenotes on completion. It also includes detailedrecommendations on the installation of flue products,inspection and smoke testing procedures.
It is essential that the building of a flue block system is carried out correctly.
- to provide a flueway that is structurally sound
- to ensure the safe operation of the gas appliance installed
- the maximum overall height of the flue must not exceed 12 metres
- flue blocks can be terminated in the roof space and ducted to a lowresistance terminal at the ridge, or to a chimney stack.
Construction Guidelines (not appliance installation):
14
It is important to follow a safetyprocedure programme i.e.
• check for damage to products
- follow installation instructions of systemand appliance
- comply with health and safety - British Standards
• decide on termination site and consideroptions available. It is recommended that the flue is installedinternally with a minimum length exposedexternally. All external runs should notexceed 3 metres in length.
• recess size to be considered dependent on appliance to be installed.
• height of flue should be assessed usingAnnex B of BS 5440-1: 2008, to amaximum height of 12 metres.
• whenever possible avoid offsets; a verticalflue is the preferred choice.
• flues should be smoke tested duringconstruction, at each floor level andfollowing installation of outlet block.The smoke test procedure is detailed inthe notice plate pack.
• a gas installer registered with theGas Safe Register must be used toconnect the appliance.
• if a hearth is required its height must betaken into consideration when calculatingthe finished height of the recess opening.
405mm Opening
3mm
3mm
3mm
3mm
3mm
3mm
67
8m
m O
peni
ng
Mortar Joint
Brick/Blockwork
10mm
215mm
215mm
10mm359mm
3mm
Hearth Level
3mm
10mm
RF1
RF2
RF3
RF3
RF1
RF1
Jo
intin
gd
eta
il
222mm
222mm
222mm
222mm
222mm
222mm
15
P
P From a structureon the roof
Above the highestpoint of intersectionwith the roof
1500mm if aridge terminal. Forany other terminal,as given inBS 5440-1:2000
Site inaccordance withBS 5440-1:2000
Q
Q
Q
Q
1500
1500
45°
700
25°
ADJ terminal location
Twin-wall metal pipe height against roof pitch
Hanson Red BankAtherstone Road, MeashamSwadlincote, Derbyshire DE12 7ELTel: 01530 270333Fax: 01530 270542
Email: [email protected]/uk
Quality Assured
Q5001
Hanson UKHanson is one of the UK’s largest suppliers of construction materials. Our products includeaggregates, asphalt, ready-mixed concrete,bricks, blocks and cement. We are part of theHeidelbergCement Group, which employs63,000 people across five continents and is the global leader in aggregates and hasleading positions in cement, concrete andheavy building products.
This brochure is printed on Satimat Silk, an FSC certified product.Contains ECF pulp sourced from well managed and sustainable forests.
All dimensions are in mm, drawings not to scale and all sizes nominal.The colours in this brochure are as true as can be obtained by the normalprinting process. Hanson Red Bank is committed to a program ofcontinuous product development and reserve the right to alterspecifications without prior notification. For further product information orassistance please telephone our freephone sales line: (0800) 3285243.
